Kobelco CK1200 (Luffing) Crawler Crane Operation & Maintenance Manual S2GK21002ZE02 – PDF DOWNLOAD

OPERATION & MAINTENANCE MANUAL

CK1200 (Luffing)

APPLICABLE BOOK CODE

: from GK04-03001 : S2GK21002ZE02

(C) Printed in Japan 2007.03

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TABLE OF CONTENTS

IMPORTANT INFORMATION 1. SAFE OPERATING PRACTICES FOR MOBILE CRANES 2. OPERATION 2.1 TERMINOLOGY OF MACHINE EACH PARTS ....................................................... 2-1 2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS ..................................... 2-2 2.2.1

HANDLING OF EACH SWITCH ........................................................................ 2-4

2.3 LUFFING JIB OPERATION...................................................................................... 2-5 2.3.1

LUFFING BOOM RAISING/LOWERING OPERATION..................................... 2-6

2.3.2

JIB RAISING/LOWERING OPERATION ........................................................... 2-7

2.3.3

HOOK RAISING/LOWERING OPERATION..................................................... 2-9

2.4 FREE FALL OPERATION ........................................................................................ 2-12

3. LOAD SAFETY DEVICE 3.1 ARRANGEMENT OF EQUIPMENTS....................................................................... 3-1 3.2 TYPE AND FUNCTIONS OF EQUIPMENTS........................................................... 3-4 3.3 CONNECTING PROCEDURE OF WIRING ............................................................. 3-11 3.3.1

LUFFING ATTACHMENT.................................................................................. 3-11

3.4 FUNCTION OF CONTROLLER/MONITOR ............................................................. 3-16 3.5 OPERATING PROCEDURE OF CONTROLLER..................................................... 3-20 3.5.1

SETTING SCREEN ........................................................................................... 3-21

3.5.2

SETTING OF THE CRANE CONFIGURATION ................................................ 3-25

3.5.3

SELECTION OF MAIN/JIB/AUX. LIFTING ........................................................ 3-30

3.5.4

SETTING OF WORKING AREA LIMIT VALUE................................................. 3-31

3.5.5

SETTING OF THE TIME ................................................................................... 3-35

3.6 WARNING ALARM AND AUTOMATIC STOP ......................................................... 3-37 3.6.1

ITEMS OF WARNING ALARM AND AUTOMATIC STOP ................................ 3-37

3.6.2

CONTENTS OF AUTOMATIC STOP ................................................................ 3-38

3.6.3

RELEASE OF AUTOMATIC STOP ................................................................... 3-41

3.7 INSPECTION............................................................................................................ 3-46 3.7.1

INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED ...................................................................... 3-46

3.7.2

INSPECTION AFTER ERECTING THE ATTACHMENT................................... 3-50

3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE..................................... 3-51 3.9 INDICATION OF ERRORS AND REMEDY ............................................................. 3-52 3.10 INDICATION OF MESSAGE AND ALARM .............................................................. 3-53 3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE ........................... 3-55

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TABLE OF CONTENTS

4. ASSEMBLY AND DISASSEMBLY OF CRANE ATTACHMENT WITH LUFFING JIB 4.1 ASSEMBLY OF LUFFING ATTACHMENT .............................................................. 4-3 4.1.1

ARRANGEMENT OF BOOM / JIB / GUY LINE................................................. 4-3

4.1.2

REMOVING CRANE BOOM AND GUY LINE ................................................... 4-12

4.1.3

INSTALLING SPECIAL INSERT BOOM (WITH IDLER SHEAVE) ................... 4-13

4.1.4

CAUTION FOR CANTILEVER .......................................................................... 4-14

4.1.5

CONNECTING LUFFING BOOM TIP ASSEMBLY ........................................... 4-14

4.1.6

INSTALLING JIB ATTACHMENT...................................................................... 4-15

4.1.7

ASSEMBLY OF JIB ........................................................................................... 4-16

4.1.8

INSTALLING STRUT GUY LINE....................................................................... 4-17

4.1.9

INSTALLING JIB HOIST WIRE ROPE.............................................................. 4-18

4.1.10 CONNECTING STRUT GUY LINE AND STRUT BACKSTOP ......................... 4-19 4.1.11 INSTALLING JIB GUY LINE.............................................................................. 4-22 4.1.12 REEVING OF FRONT AND REAR DRUM WIRE ROPES................................ 4-23 4.1.13 CONNECTING SAFETY DEVICE ..................................................................... 4-26 4.2 ERECTING THE LUFFING ATTACHMENT............................................................. 4-29 4.2.1

CONFIRMATION BEFORE ERECTING THE LUFFING ATTACHMENT ......... 4-29

4.2.2

ERECTING LUFFING ATTACHMENT .............................................................. 4-30

4.2.3

CHECK BEFORE STARTING THE WORK....................................................... 4-33

4.3 LOWERING THE ATTACHMENT ............................................................................ 4-34 4.3.1

LOWERING THE ATTACHMENT ..................................................................... 4-34

4.4 DISASSEMBLY OF LUFFING ATTACHMENT ........................................................ 4-39 4.4.1

DISCONNECTION OF WIRING FOR SAFETY DEVICE .................................. 4-39

4.4.2

WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES .................... 4-40

4.4.3

DISASSEMBLY OF JIB ..................................................................................... 4-40

4.4.4

DISASSEMBLY OF LUFFING BOOM TIP ASSEMBLY.................................... 4-43

4.4.5

DISASSEMBLING INSERT BOOM ................................................................... 4-45

4.4.6

REMOVING BASE BOOM ................................................................................ 4-45

4.5 CAUTION WHEN TRANS-PORTING LUFFING BOOM TIP ASSEMBLY ............... 4-46

5. BOOM AND GUYLINE ARRANGEMENT CHARTS WITHOUT LUFFING JIB 6. WIRE ROPE 6.1 SPECIFICATION OF WIRE ROPE .......................................................................... 6-1 6.2

WIRE ROPE LENGTH ............................................................................................ 6-1

7. MAINTENANCE 7.1 CHECKS .................................................................................................................. 7-6 7.1.1

CHECK OF ATTACHMENT .............................................................................. 7-6 2

TABLE OF CONTENTS 7.1.1.1

ATTACHMENT INSPECTIONS-DAILY OR EVERY 8 HOURS.................. 7-7

7.2 OIL/GREASE SUPPLY............................................................................................. 7-10 7.2.1

ATTACHMENT .................................................................................................. 7-10

7.2.2

GREASE............................................................................................................ 7-11

7.2.3

HYDRAULIC OIL ............................................................................................... 7-12

8. REFERENCE MATERIALS 8.1 SPECIFICATION ...................................................................................................... 8-1 8.1.1

PERFORMANCE............................................................................................... 8-1

8.2 DIMENSIONS AND WEIGHT OF EACH PARTS..................................................... 8-4 8.2.1

ATTACHMENT .................................................................................................. 8-4

8.3 ELECTRIC SCHEMATIC.......................................................................................... 8-7

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TABLE OF CONTENTS

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IMPORTANT INFORMATION

IMPORTANT INFORMATION Thank you for your purchasing KOBELCO crawler crane. Our CK series full-hydraulically operated crawler crane, is manufactured based on our many years of experience and expertise. This manual describes important information about Model CK1200.

Before operating the machine, be sure to thoroughly read this manual in order to use the machine safely and efficiently.

Do not operate or maintain this machine until you read this manual and understand the instructions.

Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death.

Always keep this manual in the operator's cab.

If it is missing or damaged, place an order to a KOBELCO authorize distributor for a replacement.

If you have any questions, please consult your KOBELCO authorize distributor.

SAFETY INFORMATION Most accidents, that occur during operation are due to neglect of precautionary measures and safety rules.

Sufficient care should be taken to avoid these accidents.

Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury to, or death of, personnel.

Precautionary measures or notes provided in this manual should be read and understood by personnel before starting each task.

Operation, inspection, and maintenance should be carefully carried out, and safety must be given first priority.

Safety labels are indicated with marks. The safety information contained in this manual is intended only general safety information.

Safety labels appear both in this manual and on the machine.

All safety labels are identified by the words "DANGER", "WARNING" and "CAUTION".

These words mean the following:

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components.

Supplementary explanation.

It is very difficult for us to forecast every danger that may occur during operation. However, safety can be ensured by operating this machine according to methods recommended by KOBELCO. While operating the machine, be sure to perform work with great care, so as not to damage the machine or allow accidents to occur.

Please continue studying this manual until proper operation is completely understood.

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CK1200 Luffing Jib

IMPORTANT INFORMATION MACHINE SERIAL NUMBER When you order repair parts or need machine repair or service, always inform us of the machine serial number (stamped on the name plate) and the total number of hours indicated on the hourmeter (located on the gauge).

HOURMETER

MACHINE SERIAL NUMBER

N o. G K 0 4 - 0 0 0 0 0 ENGINE NUMBER P11C --------------

MODEL CODE

MACHINE SERIAL NUMBER

ENTER MACHINE SERIAL NUMBER OF THIS MACHINE MACHINE MODEL

CK1200

MACHINE SERIAL No.

GK04-

ENGINE No. P11C-

WARRANTY The terms under which this machine is guaranteed are clearly defined in the accompanying WARRANTY. Trouble and damage occurring during the terms of the guarantee shall be repaired at no cost to the purchaser, according to the warranty description, if the trouble or damage is determined to be our responsibility.

However, if you use the machine contrary to the instructions of this manual, the WARRANTY does not cover any damage to the machine.

REPAIR PARTS Use genuine KOBELCO parts when servicing and repairing the machine in order to ensure proper machine performance. Important security parts are designed to ensure operator safety and to protect the machine from serious damage. These parts must be replaced according to specified maintenance schedules.

EXPLANATION OF WARNING LABELS Safety labels, shown on the following pages, are installed directly on the machine and indicate the three levels of safety precautions. Confirm the positions and contents of all safety labels before starting work.

Put them to practical use to secure safety when operating the machine, or checking and performing maintenance.

CK1200 Luffing Jib

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IMPORTANT INFORMATION HANDLING OF WARNING LABELS When the safety label is damaged or stained, order a replacement label from the designated service shop.

Do not remove the safety labels. If the surface of the safety label is soiled and/or difficult to be seen, wipe it cleanly.

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CK1200 Luffing Jib

IMPORTANT INFORMATION

CK1200 Luffing Jib

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IMPORTANT INFORMATION

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CK1200 Luffing Jib

IMPORTANT INFORMATION

CK1200 Luffing Jib

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IMPORTANT INFORMATION

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CK1200 Luffing Jib

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